Production of adhesives and other glue-like materials from biomass derived from wastewater treatment

ABSTRACT

A system and method for treatment of biomass originating from wastewater treatment biosolids to obtain valuable adhesives and composite materials is described herein. Some embodiments do not require purification of a biomass product or residue to produce an adhesive. Some embodiments comprise a treatment of post extraction biomass residue configured to produce an adhesive. Use of post extraction biomass residue adds value to alternative energy produced by extracting oil from biomass.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/877,069 entitled “System and Method for Treatment of Biomass Productsor Residues and Resulting Composition” filed Oct. 7, 2015, which claimspriority to U.S. patent application Ser. No. 14/206,577 filed Mar. 12,2014, which claims priority to the U.S. provisional application No.61/777,921, filed on Mar. 12, 2013.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM

Not Applicable.

DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and includeexemplary embodiments of the system and method for treatment of biomassproducts or residues and resulting compositions, which may be embodiedin various forms. It is to be understood that in some instances, variousaspects of the invention may be shown exaggerated or enlarged tofacilitate an understanding of the invention. Therefore the drawings maynot be to scale.

FIG. 1 illustrates an embodiment of a method of creating an adhesive.

FIG. 2 illustrates an embodiment of a method of creating an adhesive.

FIG. 3 illustrates an embodiment of a method of creating an adhesive.

FIG. 4 illustrates an embodiment of a method for creating an adhesive.

FIG. 5 illustrates an embodiment of a method of creating an adhesive.

FIG. 6 illustrates an embodiment of a method of creating and using anadhesive.

FIG. 7 illustrates an embodiment of a method of creating and using anadhesive.

FIG. 8 illustrates an embodiment of a method of creating and using anadhesive.

FIG. 9 illustrates an embodiment of a method of creating and using anadhesive.

FIG. 10 illustrates an embodiment of a method of creating and using anadhesive.

FIG. 11 illustrates an embodiment of a method of creating an adhesive.

FIG. 12 illustrates an embodiment of a method of creating an adhesive.

FIG. 13 illustrates an embodiment of a method of creating a compositeusing an adhesive.

FIG. 14 illustrates an embodiment of a method of creating a compositeusing an adhesive.

FIG. 15 illustrates an embodiment of a method of creating an adhesive.

DETAILED DESCRIPTION

The subject matter of the present invention is described withspecificity herein to meet statutory requirements. However, thedescription itself is not intended to necessarily limit the scope ofclaims. Rather, the claimed subject matter might be embodied in otherways to include different steps or combinations of steps similar to theones described in this document, in conjunction with other present orfuture technologies. Although the terms “step” and/or “block” or“module” etc. might be used herein to connote different components ofmethods or systems employed, the terms should not be interpreted asimplying any particular order among or between various steps hereindisclosed unless and except when the order of individual steps isexplicitly described.

Furthermore, the described features, structures, or characteristics maybe combined in any suitable manner in one or more embodiments. In thefollowing description, numerous specific details are provided, such asexamples of denaturant solutions, biomass, composite materials, andadditives. One skilled in the relevant art will recognize, however, thatthe method for treatment of a product or byproduct of a process and theresulting composition may be practiced without one or more of thespecific details, or with other methods, components, materials, and soforth. In other instances, well-known structures, materials, oroperations are not shown or described in detail to avoid obscuringaspects of the invention.

The schematic flow chart diagrams included herein are generally setforth as logical flow chart diagrams. As such, the depicted order andlabeled steps are indicative of one embodiment. Other steps and methodsmay be conceived that are equivalent in function, logic, or effect toone or more steps, or portions thereof, of the illustrated method fortreatment of a product or byproduct of a process and the resultingcomposition. Additionally, the format and symbols employed are providedto explain the logical steps of the method for treatment of a product orbyproduct of a process and the resulting composition and are understoodnot to limit the scope of the method. Although various arrow types andline types may be employed in the flow chart diagrams, they areunderstood not to limit the scope of the corresponding method. Indeed,some arrows or other connectors may be used to indicate only the logicalflow of the method. For instance, an arrow may indicate a waiting ormonitoring period of unspecified duration between enumerated steps ofthe depicted method. Additionally, the order in which a particularmethod occurs may or may not strictly adhere to the order of thecorresponding steps shown.

Described herein is a system and method for treatment of a product orbyproduct of a process and the resulting composition. In one embodiment,the system and method described herein comprises the creation of anadhesive from biomass. In another embodiment, the system and methoddescribed herein comprises the creation of an adhesive from postextraction algae residue. In another embodiment, the system and methoddescribed comprises the creation of an adhesive from any proteinaceousproduct or proteinaceous byproduct of any process. An example of aproteinaceous byproduct includes, but is not limited to, “postextraction algae residue.” Post extraction algae residue is a byproductfrom the process of extracting oil from algae for alternative energyproduction and other purposes. However, additional embodiments of thepresent invention may include treatment of any proteinaceous byproductof a process or any product made intentionally for this treatment.Certain embodiments of the treated biomass can be used as an adhesive.

Conventional fuel sources include fossil fuels, such as petroleum, coal,and natural gas. Fossil fuels are associated with many disadvantages,including but not limited to: limited reserves; long regenerations time;emitting carbon dioxide when burned, which may contribute to globalwarming; emitting sulfur dioxide when burned, which contributes to acidrain; environmental hazards (e.g., oil spills) during transporting,drilling, producing, and refining crude oil; and health hazards (e.g.,coal mine pollution) during removal or extraction of the fossil fuel.

In light of the many disadvantages of fossil fuels, many alternativeenergy sources have been developed, including but not limited to, solarpower, wind power, hydropower, and geothermal power. There are manydisadvantages associated with each of the above listed alternativeenergy sources. For example, solar power requires a large upfront costand requires back-up sources of energy for times when no solar input isavailable. Wind power requires large wind turbines and only generatespower when sufficient wind is present. Hydropower often requiresbuilding large, expensive dams that alter the natural environment aroundthe dam. Geothermal power requires tapping hot spots accessible withinthe Earth's crust. However, these hot spots may be challenging to locateand often occur in unstable locations, such as near volcanoes or faultlines, which are subject to earthquakes.

Another alternative energy source is biofuel, including but not limitedto biodiesel, prepared from animal fat or vegetable oil. Biodiesel is afuel comprising long-chain alkyl (methyl, propyl, or ethyl) esters.Biodiesel may be mixed with other compounds. Biodiesel can be used asfuel for biodiesel engines in automobiles, trains, or aircraft, or asheating oil for domestic and commercial boilers. Alternative energytechnologies that create liquid fuels, such as biodiesel, areparticularly valuable because they allow the energy to be safely storeduntil needed. In contrast, gaseous fuels have higher risks associatedwith their use, transport, and storage.

There are some disadvantages associated with biodiesel when biodiesel ismade from vegetable oil and/or animal fat. For example, animal fat isproduced as a result of certain types of meat processing and cooking.However, the quantity of animal fat currently produced for food purposesis not sufficient to generate the quantities of animal fat-basedbiodiesel to keep up with energy consumption demands. Also, plants andanimals needed to produce vegetable oil and animal fat for biodieselcompete with plants and animals used for human food. For example, theland on which corn, soybeans, or other plants used to create vegetableoil is a finite resource and only so much corn, soybean, and otherplants can be grown on such land. According to general supply and demandprinciples, when food suppliers and biodiesel producers compete for thelimited supplies of corn, soybeans, and other crops, the cost of suchresources for both food and fuel purposes are driven up. The same issuesarise when creating ethanol from food crops. Additionally, using foodsources for biodiesel poses ethical implications because rising foodprices may cause an increase in starvation rates, particularly inimpoverished countries.

Another alternative energy source is algae. Certain types of algae maybe used to produce a variety of biofuels, including but not limited to,biodiesel, bioethanol, biogasoline, biomethanol, biobutanol, and others.Algae can be grown without competing for land currently used for growingfood crops, since algae can grow on land that is unsuitable for othercrops or in ocean water, sewage, or wastewater. Another benefit ofbiofuel produced from algae is that algae are generally biodegradable.Additionally, many types of algae can be cultivated in a much shorterperiod of time, relative to crops that otherwise might be used forbiofuel production. Accordingly, more algae can be grown at a fasterrate than other crops that might be used for biofuel production.

A non-limiting list of places where algae may be cultivated includes anopen pond, a vertical growth/closed loop system, a closed tankbioreactor, a fermentation system, or other environments. Many differenttypes of algae, including macroalgae (e.g., seaweed) and microalgae, maybe a substrate from which oil for biofuel may be extracted. Algae knownto be capable of oil production include: Ankistrodesmus TR-87,Bacilliarophy, Botryococcus braunii, Chlorella sp., Chlorellaprotothecoides (autotrophic/heterotrophic), Chlorophyceae, CyclotellaDI-35, Crypthecodinium cohnii, Dunaliella tertiolecta, Euglena gracilis,Hantzschia DI-160, Isochrysis galbana, Nannochloris, Nannochloropsissalina, Neochloris oleoabundans, Nitzschia TR-114, Phaeodactylumtricornutum, Pleurochrysis carterae, Scenedesmus TR-84, Scenedesmusacuminatus, Scenedesmus dimorphus, Scenedesmus longispins,Schiochytrium, Stichococcus, Tetraselmis chui, Tetraselmis suecica, andThalassiosira pseudonana.

Byproducts derived from both phototrophic and heterotrophic algaestrains have been shown to have similar shear strengths when convertedto adhesives or glues. The method described herein can be performedusing algal products or byproducts that may arise from biofuelproduction, wastewater treatment, food production, algae harvested fromwaterways (including but not limited to polluted waterways such asstreams and lakes), algae cultured or harvested from wastewater, orother sources of algal products. Additionally, the method describedherein can be performed directly without any pre-processing orpre-treatment required.

During cultivation of the algae, conditions may be optimized forproliferation. In some embodiments, environmental conditions that areintended to induce increased oil storage are provided to the algae.

Algae may be harvested and processed to extract certain lipids (whichare referred to herein as “algae oil”) for production of biofuels. Insome embodiments, algae oil extraction methods comprise an oil pressstep, which comprises putting pressure on the harvested algae such thatliquid extract, comprising algae oil, emerges from the mass of algaecells. In other embodiments, algae oil extraction methods may be chosenfrom the group consisting of: ultrasonic-assisted extraction, hexanesolvent method, soxhlet extraction, supercritical fluid extraction,enzymatic extraction, osmotic shock, or any other method known in theart or discovered in the future. The liquid extract, which comprisesalgae oil, may then be processed to make biofuel. In one embodiment, theprocess performed on the liquid extract, which comprises algae oil, tomake biofuel comprises transesterification. However, in anotherembodiment, no oil extraction is performed on the biomass, whichcomprises algae.

In another embodiment, the whole biomass is used and no separation ofcomponents from the biomass is required and the method does not yieldadditional products. In another embodiment, the biomass undergoes anextraction of oil or other components, including but not limitedhigh-value components, prior to addition of the denaturant; however nofurther extractions or purifications are required.

The various methods of algae oil extraction may be classified intodisruptive or non-disruptive. Disruptive methods of algae oil extractioncomprise lysing cells by mechanical, thermal, enzymatic, or chemicalmethods. Most disruptive methods of algae oil extraction compriseemulsions and require an expensive cleanup process. Non-disruptivemethods of algae oil extraction are typically less complex thandisruptive methods, but the non-disruptive methods produce low yields oflipids or algae oil. Additionally, during algae oil extraction,particularly when using any of the disruptive methods, byproducts, suchas post extraction algae residue, may be formed.

Both disruptive and non-disruptive methods of algae oil extraction, orthe extraction of any other component or residue from the algae, producea byproduct from the components of the harvested algae that remain afterremoving the liquid extract (the byproduct that remains after theremoval of the liquid extract is referred to herein as “algae cake,”“post extraction algae residue,” or “PEAR”). PEAR, can arise from otherextraction processes other than those discussed herein. The use of theterm “PEAR” includes PEAR generated by any extraction process, whethernow known or later discovered. Further, as used herein, the term “PEAR”includes the residue from any extraction from algal biomass; PEAR couldbe extraction of lipids or any other components, including but notlimited to high-value components that are used for food and/ornutraceuticals.

Purification and/or enrichment processes may be necessary to convert abiomass, including but not limited to PEAR, or similar biowastematerial, including but not limited to forest product waste (such aschips, sawdust, etc.), bioprocessing byproducts (other byproducts ofprocessing that result in a protein containing “cake”), fibrousagricultural byproducts (such as bagasse, and corn), algal biomassesthat are wastes (such as those arising from wastewater treatment, frommunicipal waste, agricultural runoff, or aquacultural runoff), microbialbiomasses (including, but not limited to, yeast and bacteria), into aresidue that has adhesive properties. As used herein, the term “biomass”includes, but is not limited to, PEAR, biowaste materials, and othersimilar biomaterial. Purification and/or enrichment processes that maybe used to convert biomass into a residue that has adhesive properties,include but are not limited to, fermenting biomass material into aresidue, liquefaction of lignin-bearing plant material to derive oil,and phenolic fraction extraction. The adhesive that results from themethod described herein is produced from sustainable, renewable sourcesand are completely formaldehyde-free.

A disadvantage of using algae to create biofuels is that certain stepsin the cultivation, harvesting, and processing of algae are expensive.To add value to the process, efforts have been made to identifycommercial uses for PEAR, including burning the PEAR for fuel, preparingthe PEAR for use as soil fertilizer, or compounding the PEAR into animalfeed. However, the above listed uses have limited commercial value.

In one embodiment, the system and method described herein comprisemanufacturing an adhesive derived from biomass. In one embodiment, thebiomass comprises PEAR. In another embodiment, the system and methodcomprises manufacturing an adhesive from a biomaterial similar to thePEAR. In still another embodiment, the system and method comprise theconversion of biomass, resulting from the treatment of wastewater orother organic wastes, into marketable products, including, but notlimited to, adhesives or composites. In still another embodiment, themethod utilizes the whole biomass and does not require separation ofcomponents from the biomass. In still another embodiment, the methodcomprises manufacturing an adhesive derived from algae, wherein oil isnot extracted from the algae.

In one embodiment, the system and method for creating an adhesivecomprises obtaining PEAR. In one embodiment, the PEAR is obtained bycultivating algae in the environment, harvesting the algae from theenvironment, and extracting algae oil from the algae, thereby generatinga byproduct of PEAR. In another embodiment, the PEAR is obtained fromalgal products or byproducts that may arise from biofuel production,wastewater treatment, food production, algae harvested from waterways(including but not limited to polluted waterways such as streams andlakes), algae cultured or harvested from wastewater, or other sources ofalgal products. In some embodiments, the PEAR is obtained from an openpond, a vertical growth/closed loop system, a closed tank bioreactor, ora fermentation system. In some embodiments, PEAR comprises proteins,carbohydrates, small amounts of deoxyribonucleic acid (“DNA”), and othercellular components.

Any type of algae may be used to obtain the PEAR, including, but notlimited to: Ankistrodesmus TR-87, Bacilliarophy, Botryococcus braunii,Chlorella sp., Chlorella protothecoides (autotrophic/heterotrophic),Chlorophyceae, Cyclotella DI-35, Crypthecodinium cohnii, Dunaliellatertiolecta, Euglena gracilis, Hantzschia DI-160, Isochrysis galbana,Nannochloris, Nannochloropsis salina, Neochloris oleoabundans, NitzschiaTR-114, Phaeodactylum tricornutum, Pleurochrysis carterae, ScenedesmusTR-84, Scenedesmus acuminatus, Scenedesmus dimorphus, Scenedesmuslongispins, Schiochytrium, Stichococcus, Tetraselmis chui, Tetraselmissuecica, and Thalassiosira pseudonana. The algae used to create PEAR maybe any naturally occurring algae or genetically modified algae that isknown in the art or that may be discovered in the future. In oneembodiment, the algae from which the PEAR is created comprises at leastone or more of the following qualities: high algae oil content, rapidproliferation, simple to harvest, easy extraction of algae oil, low costnutrients, permits human/artificial control of grown and development,and/or minimal maintenance. In another embodiment, the algae from whichthe PEAR is obtained may be specially adapted for a specificenvironment, including but not limited to, an open pond, a verticalgrowth/closed loop system, a closed tank bioreactor, a fermentationsystem, or any other artificial or natural environment.

Particle size is an important factor in the creation of effectiveadhesives. Smaller particle sizes are easier to disperse and result instronger glues or adhesives. If a biomass, including but not limited toPEAR, does not have a fine particle size (especially if it has beendried and compacted for storage), the size can be reduced using acommon, commercially available grinder. In one embodiment, the biomassis ground into a small sized (“fine”) flour to improve the consistencyand homogeneity of the biomass. In a further embodiment, the biomass isground so that it can pass through a 100 mesh sieve. Grinding thebiomass also may permit faster and more complete denaturizationreactions. In alternate embodiments, the biomass is not ground.

Dispersing the biomass in water before denaturing leads to betterdispersion and a better adhesive because the resultant adhesive from thedenaturization process inhibits further dispersion and denaturation. Insome embodiments where the biomass is ground, the ground biomass iswetted with water. However, in alternate embodiments, the ground biomassis not wetted.

The biomass, whether ground or un-ground, is mixed with a denaturantsolution, which is a solution that will denature proteins in thebiomass, to create an adhesive mixture. The denaturant solution maycomprise a urea or alkaline solution. In one embodiment, the denaturantsolution comprises an alkaline solution. In a further embodiment, thealkaline denaturant solution comprises urea. In another embodiment, thedenaturant solution comprises an acid. In another embodiment, thedenaturant solution comprises a surfactant. In a further embodiment, thedenaturant solution comprises a surfactant and the surfactant comprisesSDS. The denaturing step of the method described herein can take placeat any temperature where there is a liquid solution. In one embodiment,the temperature for the denaturing step is between approximately −5° C.and approximately 300° C. In one embodiment, the temperature for thedenaturing step of the method is between approximately 20° C. andapproximately 70° C. In one embodiment, the time during which thebiomass is treated with the denaturant solution is between approximately0 minutes to approximately 3 hours. In a further embodiment, the biomasscomprises PEAR and the biomass is treated with the denaturant solutionbetween approximately 0 minutes and approximately 3 hours. In anotherembodiment, the time during which the biomass is treated with thedenaturant solution is between approximately 1 minute and approximately29 minutes. In a further embodiment, the biomass comprises PEAR and thebiomass is treated with the denaturant solution between approximately 1minute and approximately 29 minutes. In still another embodiment, thetime during which the biomass is treated with the denaturant solution isbetween approximately 30 minutes and approximately 3 hours. In a furtherembodiment, the biomass comprises PEAR and the biomass is treated withthe denaturant solution between approximately 30 minutes andapproximately 3 hours. In other embodiments, the temperature treatmentstep is performed at ambient temperature. In another embodiment, thetime for the temperature step is between approximately 0 seconds andapproximately 10 seconds.

Generally, if the biomass and denaturant solution mixture is treated ata higher temperature, the optimized treatment time may be shorter.Accordingly, if the biomass and denaturant solution mixture is treatedat a lower temperature, the optimized treatment time may be longer. Insome embodiments, the biomass-denaturant mixture may be maintained atapproximately room temperature (e.g., approximately 20° C. toapproximately 25° C.) at all times. In a further embodiment, the biomasscomprises PEAR and the biomass-denaturant mixture may be maintained atapproximately room temperature (e.g., approximately 20° C. toapproximately 25° C.) at all times. In other embodiments, thebiomass-denaturant mixture may be subjected to a temperature betweenapproximately 26° C. and approximately 70° C. for a duration of betweenapproximately 0 minutes and approximately 3 hours. In a furtherembodiment, the biomass comprises PEAR and the biomass-denaturantmixture may be subjected to a temperature between approximately 26° C.and approximately 70° C. for a duration of between approximately 0minutes and approximately 3 hours. In another embodiment, thebiomass-denaturant mixture is subjected to a temperature betweenapproximately 26° C. and 70° C. for a duration of between approximately1 minute and approximately 29 minutes. In a further embodiment, thebiomass comprises PEAR and the biomass-denaturant mixture is subjectedto a temperature between approximately 26° C. and 70° C. for a durationof between approximately 1 minute and approximately 29 minutes. In yetanother embodiment, the biomass-denaturant mixture is subjected to atemperature between approximately 26° C. and 70° C. for a duration ofbetween approximately 30 minutes and approximately 3 hours. In a furtherembodiment, the biomass comprises PEAR and the biomass-denaturantmixture is subjected to a temperature between approximately 26° C. and70° C. for a duration of between approximately 30 minutes andapproximately 3 hours.

The denaturant solution may comprise an acidic solution (approximatelypH<7), a basic (alkaline) solution (approximately pH>7), or a neutralsolution (approximately pH 7). In some embodiments, the denaturantsolution comprises a surfactant with a pH around approximately 7. Insome embodiments, the denaturant solution comprises an alkaline solutionwith a pH between approximately 10 and approximately 14. The use of analkaline denaturant solution minimizes corrosion and other safetyhazards. In embodiments that comprise an alkaline denaturant solution,the alkaline denaturant solution may comprise a strong base or a weakbase. Examples of strong bases that may comprise the alkaline denaturantsolution include, but are not limited to sodium hydroxide or potassiumhydroxide. Examples of weak bases that can comprise the alkalinedenaturant solution include, but are not limited to: ammonia, calciumhydroxide, or borax. In some embodiments, the denaturant solutioncomprises an alkaline denaturant solution, which comprises urea. Inother embodiments, the denaturant solution comprises an alkalinedenaturant solution, which comprises monosodium phosphate. In oneembodiment, the denaturant solution comprises an alkaline solution whichcomprises up to approximately 1 mole/L sodium hydroxide solution. Inanother embodiment, the denaturant solution comprises an alkalinesolution which comprises up to approximately 1 mole/L of potassiumhydroxide solution.

The level of denaturation of the proteins in the PEAR-denaturant mixturemay be altered by changing the temperature, the treatment time, and/orthe concentration of the constituents of the denaturant solution.

In some embodiments, after combining the biomass and denaturantsolution, the resulting mixture is treated to remove any insolublesolids, which yields an adhesive with increased transparency. In afurther embodiment, the biomass-denaturant solution mixture is filtered.In another embodiment, the biomass-denaturant solution is centrifuged.In still another embodiment, the biomass-denaturant solution isseparated by any other removal method known in the art or laterdiscovered. In some embodiments where the biomass-denaturant solution isfiltered, a relatively fine filter may be used to obtain a moretransparent mixture. In an alternative embodiment where thebiomass-denaturant solution is filtered, a coarser filter can be used toobtain a higher yield, but with decreased transparency. In someembodiments where the biomass-denaturant solution is centrifuged, alonger centrifugation time may be used to obtain a more transparentmixture. In an alternative embodiment where the biomass-denaturantsolution is centrifuged, a shorter centrifugation time may be used toobtain a higher yield, but with decreased transparency.

In some embodiments, the biomass-denaturant solution comprisesadditional components, as shown in FIG. 11. Additional components whichmay be added to the biomass-denaturant solution include, but are notlimited to, components comprising a second adhesive, a glue, apreservative, a cross-linker, aliphatic epoxy resin, a defoamer, orsodium silicate.

In some embodiments of the method, the biomass-denaturant mixtureresults in a first adhesive mixture and the first adhesive mixture isblended with a second adhesive mixture. In another embodiment of themethod, the biomass-denaturant mixture results in a first adhesivemixture and the first adhesive mixture is blended with a glue. The gluemay comprise conventional synthetic glues, such as epoxy-based orformaldehyde-based resins, or natural glues derived from animal blood,casein, soybean, or soybean flour. Formaldehyde-based resin may improvethe mechanical properties and durability of the blended first adhesiveand second adhesive mixture. Due to the thermosetting properties ofanimal blood, the use of natural glues derived from animal blood in thesecond adhesive mixture permits improved water resistance of the blendedfirst adhesive mixture and second adhesive mixture. The use of naturalglues derived from casein in the second adhesive mixture permitsimproved water resistance of the blended first adhesive mixture andsecond adhesive mixture. The use of natural glues derived from soybeanor soybean flour in the second adhesive mixture may increase thequantity of the resulting blended first adhesive mixture and secondadhesive mixture. In one embodiment, the first adhesive mixture isblended with a glue comprising an epoxy based resin. In anotherembodiment, the first adhesive mixture is blended with a glue mixturecomprising a formaldehyde-based resin. In still another embodiment, thefirst adhesive mixture is blended with a glue comprising a natural gluederived from animal blood. In another embodiment, the first adhesivemixture is blended with a glue comprising a natural glue derived fromcasein. In yet another embodiment, the first adhesive mixture is blendedwith a glue comprising a natural glue derived from soybean flour.

Some preservatives are configured to provide mold resistance. In someembodiments, the biomass-denaturant mixture is combined with apreservative. Examples of preservatives that can be combined with thebiomass-denaturant mixture include, but are not limited to,copper-8-quinolinolate, copper naphthenate, chlorinated phenol, ororthophenyl phenol. In one embodiment, the biomass comprises PEAR andthe biomass-denaturant mixture is combined with a preservativecomprising copper-8-quinolinolate. In another embodiment, the biomasscomprises PEAR and the biomass-denaturant mixture is combined with apreservative comprising copper naphthenate. In still another embodiment,the biomass comprises PEAR and the biomass-denaturant mixture iscombined with a preservative comprising chlorinated phenol. In yetanother embodiment, the biomass comprises PEAR and thebiomass-denaturant mixture is combined with a preservative comprisingorthophenyl phenol.

Cross-linkers are components configured to link one polymer chain (e.g.,protein chain, other natural polymer, or synthetic polymer) to another.Examples of methods of linking the polymer chains include, but are notlimited to, linkage via a covalent bond or an ionic bond. In someembodiments, cross-linkers are added to the biomass-denaturant mixture.In one embodiment, the cross-linker that is added is at an approximately0.1% to approximately 1% concentration. In one embodiment, thecross-linker comprises a formaldehyde donor, sulfur compound, or aninorganic complexing salt. In another embodiment, the cross-linker,which is added to the biomass-denaturant mixture, is configured toimprove water resistance. Examples of cross-linkers that are configuredto improve water resistance include, but are not limited to,cross-linkers comprising dialdehyde starch, dimethylol urea, sodiumformaldehyde bisulfite, or hexamethylenetetramine. In anotherembodiment, the cross-linker, which is added to the biomass-denaturantmixture, is configured to improve the working properties and adhesiveperformance of the biomass-denaturant mixture. In one embodiment, thecross-linker, which is added to improve the working properties oradhesive performance, comprises carbon disulfide, thiourea, ethylenetrithiocarbonate, soluble salts of cobalt, chromium, or copper.

In one embodiment, cross-linkers are added to the biomass before theaddition of the denaturant, as shown in FIG. 12. In an alternativeembodiment, the cross-linkers are added to the biomass-denaturantmixture immediately after the addition of the denaturant. In stillanother alternate embodiment, biomass is mixed with denaturant under afirst set of reaction conditions and then the cross-linker is added tothe biomass-denaturant mixture under a second set of reaction conditionsthat are different from the first set of reaction conditions.

In another embodiment, an aliphatic epoxy resin is added to thebiomass-denaturant mixture to generate a protein-epoxy copolymer. In oneembodiment, the aliphatic epoxy resin is added to the biomass-denaturantmixture and the aliphatic epoxy resin that is added is approximately 5%to approximately 20% of the weight of the biomass in thebiomass-denaturant mixture. In one embodiment, the biomass comprisesPEAR, the PEAR is ground, and the amount of aliphatic epoxy resin isadded is approximately 5% to approximately 20% of the weight of theground PEAR that comprises the biomass-denaturant mixture.

In some embodiments, a defoamer is added to the biomass-denaturantmixture. In some further embodiments, the defoamer is configured toreduce or hinder foam in the mixture. In one embodiment, the defoamercomprises an oil-based defoamer.

In some embodiments, the biomass comprises PEAR and sodium silicate isadded to the biomass-denaturant mixture to help maintain a levelviscosity for longer adhesive working life and to improve waterresistance by forming insoluble proteinates.

In some embodiments, no modification or purification to a residuederived from a biomass is necessary for the residue to be used forcreating an adhesive.

In some embodiments, no additional enrichment, meaning the addition ofadditives or modifiers, is necessary to modify the biomaterial convertedinto residue that may be used for creating an adhesive.

In some embodiments, the biomass comprises PEAR and the method comprisesutilizing separation to extract components from the biomass-denaturantmixture that may be valuable or useful for other processes orapplications.

In other embodiments, biomass comprises PEAR and the method comprisesutilizing separation to modify the biomass-denaturant mixture to improvethe properties of the product. Non-limiting examples of modificationsthat may be made to the biomass-denaturant mixture are the mass fractionof the protein may be enhanced or components with a deleterious effecton the resultant mechanical properties may be removed. In oneembodiment, the biomass comprises PEAR and the method comprises aseparation step, performed on the biomass-denaturant mixture, whichresults in the mass fraction of the protein being enhanced in thebiomass-denaturant mixture. In another embodiment, the biomass comprisesPEAR and the method comprises a separation step, performed on thebiomass-denaturant mixture, which results in the removal of at least onecomponent that has a deleterious effect on the resultant mechanicalproperties of the biomass-denaturant mixture.

The resulting product of the biomass-denaturant mixture is an adhesive(and is referred to herein as the “adhesive”). The adhesive may be usedas a binder for a composite material or materials, which include, butare not limited to, the following raw materials: a wood product, rocks,sand, asphalt, gravel, recycled paper, oyster shell, corn stalk, chickenfeather, rice husk, natural fiber, animal feed, pet feed, yard waste,agricultural wastes, or other filler materials. The adhesive can also beused as a binder in particleboard manufacturing. The adhesive may beapplied to bind one or more composite materials. Examples of methodsthat may be used to apply the adhesive include, but are not limited to:by spray, curtain coater, knife, brush, indirect roller, spreader,roller, extrusion, and any other method that is known or laterdiscovered.

In some embodiments, the biomass comprises materials other than PEAR andthe biomass is used to create a residue that comprises adhesivecharacteristics. Examples of materials that the biomass may comprise,besides PEAR, include, but are not limited to, algal or microbialproducts resulting from CO₂ sequestration, algal or microbial productsresulting from the treatment of wastewater or other organic wastes, orbiomasses that have been cultivated for this purpose.

In one embodiment, the method for treatment of biomass products orresidues adds value to a method for creating alternative energy. In oneembodiment, the method comprises treating a biomass to form a product,where the biomass comprises algal products or byproducts that may arisefrom biofuel production, wastewater treatment, food production, algaeharvested from waterways (including but not limited to pollutedwaterways such as streams and lakes), algae cultured or harvested fromwastewater, or other sources of algal products. In yet anotherembodiment, the biomass is grown for the production of adhesiveaccording to the method described herein. In a further embodiment, thebiomass does not undergo any extraction for the removal of anycomponents, and is therefore used in its entirety, and a denaturantsolution is added to said biomass to form an adhesive. In anotherembodiment, a commercial use is identified for PEAR. In yet anotherembodiment, there is no requirement for an expensive process of proteinisolation and purification for use of the PEAR. In another embodiment,the method comprises a simple process for producing an adhesive. Instill another embodiment, the method's resulting product comprises aformaldehyde-free adhesive. In yet another embodiment, the product ofthe method comprises an adhesive that is free of Volatile OrganicCompounds (VOCs). In another embodiment, the method's resulting productis an adhesive that is produced without using phenols. In anotherembodiment, the method's product comprises an adhesive that can be mixedwith cross-linkers that are configured to improve the qualities and/orquantity of the adhesive mixture. In one embodiment, the methodcomprises production of a strong adhesive. In one embodiment, the methodcomprises production of a flexible adhesive. In another embodiment, themethod comprises production of a transparent adhesive. In anotherembodiment, the method comprises production of a nearly-transparentadhesive. In one embodiment, the method comprises the production of adurable adhesive. In one embodiment, the method comprises the productionof a mold-resistant adhesive. In one embodiment, the method comprisesthe production of a water-resistant adhesive.

FIG. 1 illustrates one of the embodiments of a method comprising thecreation of an adhesive. In one embodiment of the method, method 100comprises processing algae to produce PEAR 102, as shown in FIG. 1. Inone embodiment, the method for obtaining PEAR comprises cultivatingalgae in an environment 102A, harvesting algae from the environment102B, and extracting algae oil from algae, thereby generating abyproduct of PEAR 102C, as illustrated in FIG. 2.

In one embodiment, the PEAR is ground into a fine flour to improve theconsistency and homogeneity of the PEAR 103. Grinding the PEAR maypermit faster and more complete denaturization reactions.

In one embodiment, the ground PEAR is mixed with a solution that isconfigured to denature proteins in the PEAR (herein, referred to as a“denaturant”) to create a PEAR-denaturant mixture 104. While the methodmay take place at any temperature, in some embodiments, thePEAR-denaturant mixture may be treated at a temperature condition of anytemperature between 20° C. and 70° C. for a treatment of time of betweenapproximately 0 minutes and approximately 3 hours, as shown in 106 inFIG. 2.

Generally, in embodiments where the PEAR-denaturant mixture is treatedat a higher temperature, the treatment time may be lower than inembodiments where the PEAR-denaturant mixture is treated at a lowertemperature. In some embodiments, biomass comprises PEAR and the methodcomprises maintaining the biomass-denaturant mixture at room temperature(e.g., approximately 20° C. to approximately 25° C.) at all times. Inother embodiments, the biomass comprises PEAR and the method comprisestreating the biomass-denaturant mixture at a temperature condition ofbetween approximately 26° C. and approximately 70° C. In someembodiments, the biomass comprises PEAR and the method comprisesconfiguring the temperature condition for the biomass-denaturant mixtureto be one target temperature, selected from the range betweenapproximately 26° C. and approximately 70° C., for the entire treatmenttime. In other embodiments, the biomass comprises PEAR and the methodcomprises configuring the temperature condition for thebiomass-denaturant mixture to be within approximately 2° C., plus orminus, of a target temperature, selected from the range betweenapproximately 26° C. and approximately 70° C., for the entire treatmenttime. In still other embodiments, the biomass comprises PEAR and themethod comprises configuring the treatment condition for thebiomass-denaturant mixture to be any temperature between approximately20° C. and approximately 70° C., for at least part, but not all, of thetreatment time.

In some embodiments, the method comprises adapting the level ofdenaturation of proteins by modifying at least one of the following: thetemperature condition, the treatment time, and/or the concentration ofthe denaturant.

In some embodiments, the method comprises treating thebiomass-denaturant mixture to remove any insoluble solids, which yieldsan adhesive with increased transparency. Methods 108 for treating thebiomass-denaturant mixture to remove insoluble solids, include, but arenot limited to, filtration, centrifugation, or any other removal methodknown in the art or that is later discovered. In one embodiment, thebiomass comprises PEAR and the method comprises filtering thebiomass-denaturant mixture. In one embodiment, the biomass comprisesPEAR and the method comprises centrifuging the biomass-denaturantmixture.

In some embodiments, the method comprises blending thebiomass-denaturant mixture with other adhesives (any other adhesiveother than those created by using the process disclosed herein arereferred to herein as “glues”). As shown in FIG. 4, when the biomasscomprises PEAR, other adhesives 110 that may be blended with thebiomass-denaturant mixture include, but are not limited to, glues suchas epoxy-based or formaldehyde-based resins, natural glues derived fromanimal blood, casein, or soybean flour. Formaldehyde-based resins mayimprove the mechanical properties and durability of the adhesivemixture. Natural glues derived from animal blood permits improved waterresistance of the adhesive due to the thermosetting properties of theanimal blood. Natural glues derived from casein permit improved waterresistance of the adhesive. When the biomass comprises PEAR, naturalglues derived from soybean products may increase the quantity of thebiomass-denaturant adhesive mixture. In one embodiment, the biomasscomprises PEAR and the method comprises blending the biomass-denaturantmixture with an epoxy-based resin. In one embodiment, the biomasscomprises PEAR and the method comprises blending the biomass-denaturantmixture with a formaldehyde-based resin. In an embodiment, the biomasscomprises PEAR and the mixture comprises blending the biomass-denaturantmixture with a natural glue derived from animal blood. In an embodiment,the biomass comprises PEAR and the method comprises blending thebiomass-denaturant mixture with a natural glue derived from casein. Inone embodiment, the biomass comprises PEAR and the method comprisesblending the biomass-denaturant mixture with a natural glue derived fromsoybean flour.

As illustrated in FIG. 5, in one embodiment, the biomass comprises PEARand the method comprises combining the biomass-denaturant mixture with apreservative 112. Some preservatives are configured to provide moldresistance. Preservatives that may be combined with thebiomass-denaturant mixture include, but are not limited to,preservatives comprising copper-8-quinoinolate, preservatives comprisingcopper naphthenate, preservatives comprising chlorinated phenol, and/orpreservatives comprising orthophenyl phenol. In one embodiment, thebiomass comprises PEAR and the method comprises combining a preservativecomprising copper-8-quinoinolate with the biomass-denaturant mixture. Inan embodiment, the biomass comprises PEAR and the method comprisescombining a preservative comprising copper naphthenate with thebiomass-denaturant mixture. In an embodiment, the biomass comprises PEARand the method comprises combining a preservative comprising chlorinatedphenol with the biomass-denaturant mixture. In one embodiment, thebiomass comprises PEAR and the method comprises combining a preservativecomprising orthophenyl phenol with the biomass-denaturant mixture.

In one embodiment, the method comprises adding a composite material tothe adhesive, to create a composite mixture. In one embodiment, themethod comprises using the resulting adhesive mixture as a binder for acomposite material 114, as illustrated in FIG. 6, to produce acomposite. Examples of composite material include, but are not limitedto, at least one of the following raw materials: a wood product, rocks,sand, asphalt, recycled paper, oyster shell, corn stalk, chickenfeather, rice husk, natural fiber, animal feed, pet feed, or otherfiller materials, whether currently known or later discovered. In oneembodiment, the method comprises using the resulting composite mixtureto produce a composite comprising at least one of the following: a woodproduct, rocks, sand, asphalt, recycled paper, oyster shell, corn stalk,chicken feather, rice husk, natural fiber, animal feed, pet feed, orother filler materials, whether currently known or later discovered.

One inherent difficulty with making adhesives and composites with thismethod is that the adhesive hardens and solidifies by drying orevaporation. This is done by applying heat to speed thedrying/evaporation process and by applying pressure in a mold to makethe composite more dense, to create stronger adhesion within thecomposite, and to create the desired shape. However, when water isheated and pressurized within the mold, the water will boil and cancause bubbles or cracks that reduce the strength as well as having thepotential to explode.

Several strategies and methods have been discovered to mitigate thispotentially dangerous issue. One method comprises designing compositemixtures with significant porosity to allow for the steam that iscreated upon heating and pressurization to exit the composite materialeasily. Another method comprises limiting the amount of water used inthe adhesive and/or the composite mixture so that the minimum amount ofwater required to disperse and denature the protein in the biomass isused. Yet another method comprises limiting the amount of adhesive usedin the composite mixture so that the amount of adhesive used is kept lowenough so as to not seal off the porosity in the composite. Limiting theamount of adhesive also reduces the amount of water that needs toevaporate. However, even with using a limited amount of adhesive, themethod described herein has been used to make particleboard compositesthat have similar flexural rigidity and strength to conventionalparticleboards. Another method comprises controlling the amount ofcomposite mixture and the resulting thickness of the composite mixturein the mold. However, limiting the amount of composite mixture and thethickness of the composite mixture in the mold makes it difficult toproduce large, thick composites that are completely dried and hardenedin a single hot press cycle. One embodiment of the method comprises hotpressing the composite mixture to form a composite, as shown in FIG. 13.A further embodiment of the method comprises compressing individuallayers of composite mixture to form a first composite layer, forming asecond composite layer using the same method as the formation of thefirst composite layer, applying an adhesive between the first and secondcomposite layers, then hot pressing the first and second compositelayers together to create a composite that is not limited in itsthickness by the water evaporation/boiling issue. This method results ina thicker, larger composite than those that could be created by formingthe composite in a single hot press cycle. This method comprises usingthe adhesives with the same chemical composition to both make thecomposite layers and to adhere the composite layers together. In analternate embodiment, the method comprises using the adhesive to createthe composite layers and using a glue to adhere the composite layerstogether. In another alternate embodiment, while the adhesive to makethe composite layer, the first adhesive, has the same components as theadhesive used to adhere the composite layers together, the secondadhesive, the concentrations of the components in first adhesive aredifferent from the concentration of the components in the secondadhesive. In still another embodiment, the adhesive used to make thecomposite layers has different components from the adhesive used toadhere the composite layers together. In an alternate embodiment, anadhesive is placed on the first composite layer and then the secondcomposite layer at least a minimal amount of pressure is applied to pushthe second composite layer against the adhesive on the first compositelayer, but with no hot pressing. In another embodiment, an adhesive isadded to the first composite layer and the second composite layer isclamped to the first composite layer, so that the adhesive is locatedbetween the first composite layer and the second composite layer. In oneembodiment, the clamping pressure is between approximately 80 psi andapproximately 120 psi. As shown in FIG. 14, a further alternative methodof making a composite comprises hot pressing the composite mixture toform a single layer of composite, then adding additional compositemixture to this layer and performing an additional hot pressing step. Inone embodiment, the method comprises subjecting a layer of compositemixture to a hot pressing step to form a layer of composite, then addinganother layer of composite mixture and performing another hot pressingstep to create an additional layer of composite on the first layer ofcomposite. In another embodiment, the method comprises performing a hotpressing step on a composite mixture to form a first composite layer,adding an additional composite mixture to the first composite layer andthen performing another hot pressing step, and repeating the addition ofthe composite mixture followed by a hot pressing step at least oneadditional time to form a final composite.

In one embodiment, the hot pressing step is performed for a duration ofapproximately 8 minutes to compact the composite into a solid specimen.

In some embodiments, the hot pressing of these composites is done at ahigher temperature to allow for faster drying up to the point where thesurface of the composite burns or discolors. For embodiments wherein thecomposite material comprises sawdust and bagasse, the temperature forthe hot pressing step is approximately 350° F. However, depending on thecomposite material used, the temperature for the hot pressing step maybe different.

In some embodiments, the pressure for the hot pressing step is maximizedto improve thermal contact and conductivity, to create a densercomposite, and to create better adhesion. However, the pressure can onlybe increased to a certain point before stress cracks, which are highlydetrimental to mechanical and esthetic properties, form in thecompressed product. In one embodiment of the method, a clamping pressureof approximately 80 psi to approximately 120 psi is applied during thehot pressing step. However the optimal pressure will vary based on thecomposite material and adhesive used.

If composites are left unconstrained under ambient conditions for aperiod of days after the hot pressing step, they may warp significantly.The warping is likely due to the loss of residual water and therelaxation of internal stresses developed in the hot pressing step.Three methods have been found to minimize or eliminate the warping. Inone embodiment, the method comprises performing the hot press step for asignificantly longer time period than 8 minutes. While this iseffective, it is often undesirable due to the increased cycle time. Inanother embodiment, the method comprises performing the hot press stepon the adhesive-composite material mixture to form a composite, clampingthe recently hot pressed composite so that they cannot warp, and thenheating the clamped composite to approximately 105° C., and maintainingthe clamping and the temperature for approximately 20 hours toapproximately 48 hours, to eliminate residual water and internalstresses. In yet another embodiment, the method comprises the creationof a multiple-layered composite through the hot pressing of a compositemixture to create a first layer of composite, then the addition ofanother layer of composite mixture followed by hot pressing the firstlayer composite and the newly added composite mixture. The multiplelayered composite did not exhibit any substantial warping. In oneembodiment, the hot pressing step comprises using a press time of longerthan approximately 8 minutes followed by clamping the recently hotpressed composite for a period of between approximately 20 hours toapproximately 48 hours. In a further embodiment, the hot pressing stepcomprises using a press time of longer than approximately 8 minutes,clamping the recently hot pressed composite, and heating the clampedrecently hot pressed composite to approximately 105° C., and maintainingthe temperature and the clamping for a period between approximately 20hours and approximately 48 hours. In an alternate embodiment, the hotpressing step comprises using a press time of less than approximately 8minutes. In another embodiment, the method comprises a hot pressing stepcomprising a press time of less than approximately 8 minutes, followedby a clamping step comprising clamping the recently hot pressedcomposite for a period between approximately 20 hours to approximately48 hours. In yet another embodiment, the method comprises a hot pressingstep comprising a press time of less than approximately 8 minutes,followed by a clamping step comprising clamping the recently hot pressedcomposite for a period of 20 hours to 48 hours at a temperature ofapproximately 105° C. The various embodiments for hot pressing may beused either to make a single composite, a single composite layer, or tocreate multiple layers of composite. Additionally, the clamping step maybe used to make a single composite, a single composite layer, or tocreate multiple layers of composite.

Older shear strength tests indicated that a maximum shear strength ofthe adhesive was obtained at a reaction time of approximately 60minutes. Viscosity is an indicator of the adhesive strength. Recentviscometry experiments suggest that the viscosity of the adhesivemixture formed by the method described herein monotonically decreasesafter mixing. The recent viscometry experiments indicate for maximumadhesive strength, the adhesive mixture should be mixed with a compositematerial and hot pressed as soon as possible after complete dispersionand the mixing of the biomass with a strong base.

Examples of specific methods, and compositions and composites createdfrom those methods, are provided below. These examples are illustrativeonly and are not intended to be limiting.

Example 1

In some embodiments, approximately 1 gram of PEAR may be mixed with adenaturant; the denaturant comprising approximately 30 mL ofapproximately 0.1M NaOH. The resulting PEAR-denaturant mixture may betreated at a temperature condition of approximately 50° C. for atreatment time of approximately one hour.

Example 2

In some embodiments, approximately 1 gram of PEAR may be mixed with adenaturant; the denaturant comprising approximately 30 mL ofapproximately 0.1 M NaOH. The resulting PEAR-denaturant mixture may betreated at a temperature condition of approximately 50° C. for atreatment time of approximately one hour. In an additional step, thePEAR-denaturant mixture is centrifuged to remove insoluble solids.

Example 3

In some embodiments, approximately 3 grams of PEAR may be mixed with adenaturant; the denaturant comprising approximately 30 mL ofapproximately 3M urea. The resulting PEAR-denaturant mixture may betreated at a temperature condition of approximately 50° C. for atreatment time of approximately two hours. In an additional step, thePEAR-denaturant mixture is filtered to remove insoluble solids. Althoughany suitable filter may be used for this filtering step, onenon-limiting example of a filter that may be used is a simple coarsepaper filter.

Additional steps may be performed to configure the PEAR-denaturantmixture for use as an adhesive on a particular substrate. Examples ofsubstrates include, but are not limited to, paper, label, or other itemsthat the user wishes to adhere together. For example, in one embodiment,the method comprises applying the PEAR-denaturant mixture a surface of afirst substrate unit (e.g., one piece of paper or one side of a label).In some embodiments, a second substrate unit is placed adjacent to thePEAR-denaturant mixture that was applied to the first substrate unit,such that the PEAR-denaturant mixture is sandwiched between the firstsubstrate unit and the second substrate unit. Optionally, the firstsubstrate unit, the second substrate unit, and the PEAR-denaturantmixture (collectively with the first substrate unit and the secondsubstrate unit, a “multiple substrate unit”) may be clamped together orto a support component (e.g., a shelf, rack, board, etc.) using at leastone clamping instrument.

The multiple substrate unit may be permitted to dry. In someembodiments, the drying process may constitute merely positioning themultiple substrate unit on a support unit, either with or without usinga clamping instrument), and then not altering the position of themultiple substrate unit for a period of time. In some embodiments, thedrying process may be accelerated by positioning the multiple substrateunit in a heating element, such as a laboratory oven, industrial oven,or any other unit that is configured to emit heat, whether currentlyknown or developed in the future. In one embodiment, the drying processmay include a drying temperature of approximately 105° C. for a dryingtime of approximately 24 hours. In some embodiments, the methodcomprises providing a mixture having a tensile strength that issufficient to permit casual handling of the multiple substrate unitwithout resulting in the separation of the first substrate unit from thesecond substrate unit.

Example 5

In some embodiments, approximately 15 grams of PEAR may be mixed with adenaturant; the denaturant comprising approximately 225 mL ofapproximately 1M NaOH. The PEAR-denaturant mixture may be treated at atemperature condition of approximately 50° C. for a treatment time ofapproximately 1 hour.

Example 6

In some embodiments, approximately 15 grams of PEAR may be mixed with adenaturant; the denaturant comprising approximately 225 mL ofapproximately 1 M NaOH. The PEAR-denaturant mixture may be treated at atemperature condition of approximately 50° C. for a treatment time ofapproximately one hour. Subsequently, the resulting mixture may bemerged with approximately 300 grams of wood product, to obtain amixture-wood product composite. In one embodiment, the wood productcomprises approximately 70% core furnish (coarse wood particles) andapproximately 30% face furnish.

In some embodiments, the mixture-wood product may require pressing. Themixture-wood product composite may be pressed at a pressing temperatureof approximately 450° F. for a pressing time of approximately 2 minutesto approximately 6 minutes, or until cessation of audible boiling. Thepressure applied in the pressing step may range from betweenapproximately 1300 pounds and approximately 2000 pounds over anapproximately 5″×5″ plate. Generally, a higher pressure in theapproximately 1300 pound to approximately 2000 pound range is configuredto yield more dense and more rigid composites, while lower pressureswithin the range are configured to yield less dense and less rigidcomposites. In one embodiment, the press may be de-pressured slowly tomanage the release of steam.

Various combinations of the steps illustrated in FIG. 1 through FIG. 6and FIGS. 11 and 12 may be conducted to produce an adhesive. Alternativeadditional embodiments of the method that comprise a combination ofsteps are illustrated in FIG. 7 through FIG. 10 and FIGS. 13 and 14.

FIG. 7 illustrates another embodiment of the method. In FIG. 7, themethod comprises a purification step and an enrichment step to producethe PEAR that may be used to form an adhesive.

FIG. 8 illustrates an additional embodiment of the method. In FIG. 8,the purification step is not necessary to produce the PEAR that may beused to form an adhesive.

FIG. 9 illustrates an additional embodiment of the method. In FIG. 9,the enrichment step is not necessary to produce the PEAR that may beused to form an adhesive.

FIG. 10 illustrates another embodiment of the method. In FIG. 10,neither a purification step nor an enrichment step is necessary toproduce the PEAR that may be used to form an adhesive.

In addition, in some embodiments of the method, the method comprisesadhesives generated by any of the embodiments of the methods, orcombinations of the methods, described herein.

For the purpose of understanding the method for treatment of biomassproducts or residues and resulting compositions, references are made inthe text to exemplary embodiments of a method, only some of which aredescribed herein. It should be understood that no limitations on thescope of the invention are intended by describing these exemplaryembodiments. One of ordinary skill in the art will readily appreciatethat alternate but functionally equivalent components, materials,designs, and equipment may be used. The inclusion of additional elementsmay be deemed readily apparent and obvious to one of ordinary skill inthe art. Specific elements disclosed herein are not to be interpreted aslimiting, but rather as a basis for the claims and as a representativebasis for teaching one of ordinary skill in the art to employ thepresent invention.

Reference throughout this specification to features, advantages, orsimilar language does not imply that all of the features and advantagesthat may be realized should be or are in any single embodiment. Rather,language referring to the features and advantages is understood to meanthat a specific feature, advantage, or characteristic described inconnection with an embodiment is included in at least one embodiment.Thus, discussion of the features and advantages, and similar language,throughout this specification may, but do not necessarily, refer to thesame embodiment.

Furthermore, the described features, advantages, and characteristics maybe combined in any suitable manner in one or more embodiments. Oneskilled in the relevant art will recognize that the method for treatmentof biomass products or residues and resulting compositions may bepracticed without one or more of the specific features or advantages ofa particular embodiment. In other instances, additional features andadvantages may be recognized in certain embodiments that may not bepresent in all embodiments.

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment. Thus, appearances of the phrases“in one embodiment,” “in an embodiment,” and similar language throughoutthis specification may, but do not necessarily, all refer to the sameembodiment.

It should be understood that the drawings are not necessarily to scale;instead, emphasis has been placed upon illustrating the principles ofthe invention. In addition, in the embodiments depicted herein, likereference numerals in the various drawings refer to identical or nearidentical structural elements.

Moreover, the terms “substantially” or “approximately” as used hereinmay be applied to modify any quantitative representation that couldpermissibly vary without resulting in a change to the basic function towhich it is related.

1. A method for producing an adhesive from biomass products or residues,comprising the steps of: a. obtaining a biomass comprising wastewatertreatment biosolids; b. extracting a component from said biomass,thereby generating a byproduct of said biomass; c. grinding saidbyproduct of said biomass into a ground biomass byproduct; d. wettingsaid ground biomass byproduct; and e. mixing said wetted biomassbyproduct with a solution, said solution configured to denature proteinsin said biomass byproduct to form an adhesive mixture.
 2. The method ofclaim 1, further comprising a step of heating the adhesive mixture at atemperature condition between approximately 20° C. and approximately 70°C. for a reaction time of between approximately 0 seconds andapproximately 3 hours.
 3. The method of claim 1, wherein said mixingstep further comprises regulating a level of denaturation of proteins insaid biomass byproduct by adjusting at least one parameter, said atleast one parameter selected from the group of: a temperature condition,a reaction time, and a concentration of said solution wherein saidconcentration of the solution is no greater than 1 mole per liter. 4.The method of claim 1, further comprising a step of adding apreservative to said adhesive mixture.
 5. The method of claim 1, furthercomprising a step of adding cross-linkers to said adhesive mixturebefore said mixing step.